Rotary agitator providing low noise operation

ABSTRACT

A rotary agitator includes a body having an axis of rotation. The body also includes a projecting cleaning element extending along the body at an angle relative to the axis of rotation of greater than 45 degrees. The projecting cleaning element may take the form of, for example, a beater bar, a flexible wiper, a brush and a series of bristle tufts.

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/633,005 filed on 3 Dec. 2004.

TECHNICAL FIELD

The present invention relates generally to the floor care equipment field and, more particularly, to a rotary agitator with a cleaning element projecting at a certain angle for low noise operation, a floor care appliance equipped with such a rotary agitator and to a method of producing a low noise rotary agitator.

BACKGROUND OF THE INVENTION

A vacuum cleaner is an electrically powered, mechanical appliance utilized for the dry removal of dust and loose dirt from carpets, rugs, fabrics and other surfaces. Vacuum cleaners have been widely utilized for years in domestic and industrial cleaning applications.

In operation, a pressure drop is utilized to force air entrained with loose dirt and dust into the nozzle of the vacuum cleaner. The dust and dirt laden air is then drawn through a bag or dirt cup which traps and retains the dirt. The air is then exhausted by electric fan through an additional filter to remove relatively fine particles. It is this fan that provides the air pressure drop or vacuum that provides the cleaning action.

In order to loosen dirt and debris from the nap of an underlying carpet, it has also long been known to equip vacuum cleaners with rotary agitators. Such rotary agitators include projecting cleaning elements such as beater bars, wipers, brushes and bristle tufts to provide a brushing and sweeping action to the carpet nap during agitator rotation. These cleaning elements have been provided at a relatively small angle to the rotational axis of the rotary agitator of generally about 20 degrees. Generally this has been done in an effort to reduce manufacturing costs. For example, by providing tufted bristles at a small angle of 20 degrees or less, fewer bristle tufts are required to provide a “continuous” cleaning element across the entire length of the rotary agitator.

The present invention relates to a rotary agitator incorporating cleaning structures that project at a certain angle to the rotational axis of the rotary agitator so as to provide good cleaning action in combination with gentle carpet cleaning and low noise operation.

SUMMARY OF THE INVENTION

In accordance with the purposes of the present invention as described herein, a rotary agitator is provided which functions to simultaneously provide good cleaning efficiency, gentle cleaning action and low noise operation. The rotary agitator includes a body having an axis of rotation. The body includes a projecting cleaning element extending along the body at an angle relative to the axis of rotation of greater than 45 degrees, typically between about 55 degrees and about 80 degrees, more typically between about 60 to about 70 degrees and most typically about 65 degrees. The projecting cleaning element may take a number of forms including but not limited to a beater bar, a flexible wiper, a brush and a series of bristle tufts.

In accordance with another aspect of the present invention a method is provided for producing a low noise rotary agitator. The method comprises producing the agitator with a body having an axis of rotation and a projecting cleaning element extending along the body at an angle relative to the axis of rotation of greater than 45 degrees and typically between about 55 to about 80 degrees, more typically between about 60 to 70 degrees and most typically about 65 degrees.

In accordance with still another aspect of the present invention a rug or carpet cleaning appliance is provided. That appliance comprises a a housing and a suction generator, a dirt collection vessel and a rotary agitator all carried on that housing. The rotary agitator includes a body having an axis of rotation. The body includes a projecting cleaning element extending along the body at an angle relative to the axis of rotation of greater than 45 degrees.

In the following description there is shown and described several possible embodiments of the invention, simply by way of illustration of some of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments, and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated in and forming a part of the specification, illustrate several aspects of the present invention, and together with the description serve to explain certain principles of the invention. In the drawings:

FIG. 1 is a perspective view of one possible embodiment of a rotary agitator of the present invention;

FIG. 2 is a schematical side elevational view illustrating the angle of the cleaning element provided on the rotary agitator of the present invention;

FIG. 3 is a perspective view of an upright vacuum cleaner incorporating the rotary agitator of the present invention; and

FIG. 4 is a detailed perspective view of one possible embodiment of the dirt collector or dirt collection vessel in the apparatus illustrated in FIG. 3.

Reference will now be made in detail to the illustrated embodiments of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference is now made to FIG. 1 illustrating the rotary agitator 10 of the present invention. The rotary agitator 10 includes a body 12. In the illustrated embodiment the body 12 is cylindrical in shape. It should be appreciated, however, that other shapes may be utilized. The body 12 may be made from plastic such as nylon or ABS, metal such as aluminum or other appropriate material such as wood. As best illustrated in FIG. 2 the body 12 has an axis of rotation 14. The body 12 also includes a projecting cleaning element 16 that extends along the body at a lead angle ⊖ relative to the axis of rotation of greater than 45 degrees, typically from 55 to 80 degrees, more typically from 60 to 70 degrees and most typically about 65 degrees. The projecting cleaning element 16 may comprise any number of structures suitable for beating or brushing dirt and debris from the nap of an underlying rug or carpet. Such structures include but are not limited to a beater bar, a flexible wiper and a brush (see FIG. 1) and a series of bristle tufts (see FIG. 2).

By providing the projecting cleaning element 16 at the indicated lead angle ⊖, each portion of the cleaning element engaging the nap of the underlying rug or carpet moves through a relatively small approach angle A (see FIG. 2). Of course, the greater the lead angle ⊖, the smaller the approach angle A. The smaller the approach angle A the more gradually the projecting cleaning element 16 brushes nap to the side and loosens embedded dirt so that dirt and debris at the base of the nap is more easily drawn into the suction airflow of the floor cleaning appliance to which the rotary agitator 10 is connected. The more gradual brushing action reduces both wear on the carpet and the noise generated by the agitator 10 during vacuum cleaner operation.

Stated another way, a number of benefits are provided by the agitator 10 of the present invention. The noise of the cleaning operation is reduced when compared to rotary agitators of the prior art which typically include projecting cleaning elements at an angle to the axis of rotation of between 20 and 30 degrees. As a further benefit or advantage, the present invention still provides the efficient and effective cleaning action of such a rotary agitator but does so while producing significantly less noise and less carpet wear.

Reference is now made to FIG. 3 illustrating an upright vacuum cleaner 20 incorporating the rotary agitator 10 of the present invention. It should be noted that this is just one possible floor care appliance of the present invention and that other possible embodiments include but are not limited to canister vacuum cleaners, handheld vacuum cleaners and extractors.

The vacuum cleaner 20 includes a housing, generally designated by reference numeral 22, including a nozzle assembly 24 and a handle assembly 26. As is known in the art, the handle assembly 26 is pivotally connected to the nozzle assembly 24 to aid the operator in manipulating the vacuum cleaner 20 back and forth across the floor. Wheels (not shown) carried on the housing 22 allow the vacuum cleaner 20 to be moved smoothly across the floor. As illustrated, the nozzle assembly 24 is equipped with a nozzle inlet 28. The rotary agitator 10 is mounted for rotation on the nozzle assembly 24 across the nozzle inlet 28 by means of an end cap and bearing assembly 40 provided at each end of the agitator 10 in a manner well known in the art (note, only one such end cap and bearing assembly 40 is illustrated in FIG. 2).

The handle assembly 26 houses a suction generator 32 (i.e. a fan and motor assembly) and a dirt collector 34 having an internal dirt collection chamber. In the illustrated embodiment, the dirt collector 34 take the form of a cylindrical dirt cup with a tangentially directed inlet 46, an axially directed outlet 48 and an internal filter 50 positioned over the outlet (see FIG. 4). Such an arrangement generates a cyclonic airstream in the dirt cup 34 that functions to remove dirt and debris from the airstream for more efficient cleaning in a manner well known in the art. Of course, dirt cups of other shapes and design could be utilized as could a standard, disposable filter bag.

The handle assembly 26 also includes a control stalk 38 and an actuator switch 36 for turning the vacuum cleaner 20 on and off and thereby driving the rotary agitator 10 and the suction generator 32. The vacuum cleaner 20 may be powered by electricity from an electrical wall outlet through a power cord (not shown) or by means of an onboard battery.

In operation, the rotary agitator 10 quietly and efficiently brushes dirt and debris from the nap of an underlying carpet. That loosened dirt and debris is then drawn into the dirt collector 34 by means of the suction generator 32. Dirt and debris is trapped in the dirt collector 34 and the now clean air is directed over the motor of the suction generator 32 before being exhausted into the environment through the exhaust vent 42.

The foregoing description of a preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. For example, while the illustrated embodiment is an upright vacuum cleaner 20, the present invention also relates to and includes canister and handheld vacuum cleaners as well as extractors. Further, while the illustrated embodiment is a “clean air” system with a suction generator 32 downstream from the dirt collector 34, the present invention also includes “dirty air” systems where the suction generator is located upstream of the dirt collector. Further, while the illustrated vacuum cleaner 20 includes one rotary agitator 10, it could include two or more rotary agitators if desired.

The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. The drawings and preferred embodiments do not and are not intended to limit the ordinary meaning of the claims and their fair and broad interpretation in any way. 

1. A rotary agitator, comprising: a body having an axis of rotation, said body including a projecting cleaning element extending along said body at an angle relative to said axis of rotation of greater than 45 degrees.
 2. The rotary agitator of claim 1 wherein said projecting cleaning element is a beater bar.
 3. The rotary agitator of claim 1, wherein said projecting cleaning element is a flexible wiper.
 4. The rotary agitator of claim 1, wherein said projecting cleaning element is a brush.
 5. The rotary agitator of claim 1, wherein said projecting cleaning element is a series of bristle tufts.
 6. A rotary agitator, comprising: a body having an axis of rotation, said body including a projecting cleaning element extending along said body at an angle relative to said axis of rotation of between about 55 degrees and about 80 degrees.
 7. The rotary agitator of claim 6 wherein said projecting cleaning element is a beater bar.
 8. The rotary agitator of claim 6, wherein said projecting cleaning element is a flexible wiper.
 9. The rotary agitator of claim 6, wherein said projecting cleaning element is a brush.
 10. The rotary agitator of claim 6, wherein said projecting cleaning element is a series of bristle tufts.
 11. A rotary agitator, comprising: a body having an axis of rotation, said body including a projecting cleaning element extending along said body at an angle relative to said axis of rotation of between about 60 degrees to about 70 degrees.
 12. The rotary agitator of claim 11 wherein said projecting cleaning element is a beater bar.
 13. The rotary agitator of claim 11, wherein said projecting cleaning element is a flexible wiper.
 14. The rotary agitator of claim 11, wherein said projecting cleaning element is a brush.
 15. The rotary agitator of claim 11, wherein said projecting cleaning element is a series of bristle tufts.
 16. A rotary agitator, comprising: a body having an axis of rotation, said body including a projecting cleaning element extending along said body at an angle relative to said centerline of about 65 degrees.
 17. The rotary agitator of claim 16 wherein said projecting cleaning element is a beater bar.
 18. The rotary agitator of claim 16, wherein said projecting cleaning element is a flexible wiper.
 19. The rotary agitator of claim 16, wherein said projecting cleaning element is a brush.
 20. The rotary agitator of claim 16, wherein said projecting cleaning element is a series of bristle tufts.
 21. A method of producing a low noise rotary agitator, comprising: producing said agitator with a body having an axis of rotation and a projecting cleaning element having an angle relative to said axis of rotation of greater than 45 degrees.
 22. A rug or carpet cleaning appliance, comprising: a housing; a suction generator carried on said housing; a dirt collection vessel carried on said housing; and a rotary agitator carried on said housing, said rotary agitator including a body having an axis of rotation, said body also including a projecting cleaning element extending along said body at an angle relative to said axis of rotation of greater than 45 degrees. 